38 gallon tank install in a 92-96 (97HD)

Well that sucks. I did a three inch single system on mine, with an offset/offset muffler. The tailpipe is about an inch away from the tank, so I may change the muffler to a center/center. The current muffler is too quiet anyway.

Well that sucks. I did a three inch single system on mine, with an offset/offset muffler. The tailpipe is about an inch away from the tank, so I may change the muffler to a center/center. The current muffler is too quiet anyway.

Mine is 3 inch true-dual with series 10 flowmasters(nice and loud). It is a custom made exhaust that was on the truck when I got it. It ends right behind each rear tire(you can see it in my sig photo). But when it goes over the axle, it comes back down right under each front corner of the rear tank, so it doesn't leave any room for a bigger tank, or even my full size spare

I think they are about 12 inch tips welded on the exits. Probably one of my favorite things about my truck is the exhaust, I have never heard anything else like it.

When I bought the truck the PO said he got it done from stock for about $400. That included cats, mufflers, and the dual pipes. I was surprised, I thought for sure a setup like this would be a bit more $$$

I could try to see if the brackets holding up the exhaust could be adjusted lower without actually cutting pipes. I'll get under there again tomorrow and see If there is enough room to work with before I rule out this tank for sure.

I'm glad you replied, I forgot to update this. I found an additional issue with extending the lines, and a quick fix.

I didn't realize that the hanger tubes have a bracket that screws to the fuel pump module, to prevent it from sliding off the tubes. I found out the hard way, my fpm slipped off the tubes, causing a no start/very low fuel pressure issue.

I made a bracket (really just a piece of stainless sheetmetal) that bolts to the original hanger tube bracket, and screws to the plastic fpm.

Nice! I really need a bigger tank in my truck I'm always filling it every few days with all the traveling i have been doing for work and this would make it so much nicer! not to mention that my gad gauge is wrong. do you have to modify the fuel pump or is there one that can be purchased for the 38 gallon tank?I think mine is on its way out anyway so i would rather just replace it.

Correct on the upper tank straps. Mine were a little rusty, and I had the bed off so I figured why not.

The bronco hanger may or may not work in this application. I think the Bronco tank is deeper than this 38 gallon tank. I had a used Bronco hanger to work with, but it didn't appear as though I could cut the required amount out of it to be able to use it.

Nice! I really need a bigger tank in my truck I'm always filling it every few days with all the traveling i have been doing for work and this would make it so much nicer! not to mention that my gad gauge is wrong. do you have to modify the fuel pump or is there one that can be purchased for the 38 gallon tank?I think mine is on its way out anyway so i would rather just replace it.

The only modifications are as shown with the tubing on the hanger. The fuel pump is encased in the white plastic can, which I had called the fuel pump module. I'm sure there's a name for it, but that's what I called it.

As far as I know, there's no "drop in" replacement pump/hanger assembly that exists for using a 38 gallon tank in our body style.

Great Write Up Bob. With dual tanks changing the rear tank to a 38 gallon would give me 57 gallons total. At 17-19 mpg on the road that is a 1000 miles non stop for gas. Have to put a pisser in the cab I guess.
Thanks again Bob great write up.

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